ABSTRACT BOOK...ABSTRACT BOOK ADDITIVE MANUFACTURING + CERAMICS = INNOVATION Powered by: 2 ABOUT A VIRTUAL WELCOME BY THE ORGANIZERS 3 PROGRAM 4 A …

ABSTRACT BOOK

www.am-ceramics.dkg.de

ADDITIVE MANUFACTURING + CERAMICS = INNOVATION 2Powered by:

ABOUT

A VIRTUAL WELCOME BY THE ORGANIZERS 3

PROGRAM 4

A VIEW BEYOND

DIGITAL LAB TOUR: ADDITIVE MANUFACTURING TECHNOLOGIES AT FRAUNHOFER IKTS 5

VIDEO SNACKS AND INSIGHTS 5

SESSION 1: COMPONENTS AND THERMAL PROCESSING

Fürderer, T.: The rocky road from idea to product: product development using the example of multiphase ceramics 8

Melzer, Ch.: Ceramic packages for magneto-resistive sensors in space applications 9

Schenk, Ch.: Advances in the debinding and sintering of ceramics under air and modified spaces 10

SESSION 2: DATA COLLECTION AND PROCESSING

Wagner, D.; Abel, J.: Non-contact infrared temperature measurement in inline process control 11

Juhrisch, M.: All in practice: intelligent solutions for the sustainable optimization of ceramic process chains 13

Lang, V.: Data acquisition and analysis for process monitoring in the field of additive manufacturing 14

SESSION 3: TECHNICAL AND MEDICAL APPLICATIONS

Weber, F.: Osteoconduction and bone augmentation: When 3D-printed designs meet bone biology 15

Paterlini, A.: Tribo-mechanical behavior of semi-porous parts for small joint arthroplasty 16

Benson, N.: Ceramic additive manufacturing for radar applications 17

SESSION 4: NEW DEVELOPMENTS IN MATERIAL AND TECHNOLOGY

Konegger, Th.: Additive manufacturing of aluminium nitride ceramics 18

Weingarten, S.: Multi Material Jetting of ceramic components 19

Adolfsson. E.: Additive manufacturing of zirconia ceramics 20

CONTENTS

PRESENTATIONS

KEYNOTES

Michaelis, A.: Multi-materials additive manufacturing and 5D printing 6

Homa, J.: Empowering digital transformation with additive manufacturing technologies 7


LITHOZ GMBH MESSE MÜNCHEN GMBH FRAUNHOFER IKTS

It is our great pleasure to welcome you to AM Ceramics ceramitec conference 2020! We are looking forward to working with ceramitec conference for the second year in a row, as well as with Fraunhofer IKTS. We are greatly looking forward to joining with the Fraunhofer IKTS to hold an open and motivating conference in Dresden, full of opportunities for discussions and networking. While the coronavirus pan-demic may have changed those circumstances somewhat, it has also opened the door to new possibilities, with many more guests now able to join us not only from within Europe but also further afield, including South Korea, Egypt, the USA and Brazil. The speakers in the program are uniquely placed to debate different aspects of ceramics and AM, they will highlight the key themes, trends and current practices for the audience.

We are looking forward to an interesting virtual conference with exciting lectures and lively participation from the audience.

At Messe München, we are currently developing and piloting several new digital event formats. I am pleased that you have decided to join us for this purely digital AM ceramics confer-ence as well. Together with our partners, Lithoz GmbH and Fraunhofer IKTS, we arranged a comprehensive program following the two main tracks "new industrial use opportuni-ties for ceramics" and "additive manufacturing processes". Look forward to a top-class international field of speakers, featuring leading experts from science and industry. Experience the latest achievements in the ceramics industry and discover the possibilities of using a millennium-old material to provide solutions for future challenges in a wide range of application industries.

I wish you an insightful AM ceramics and ceramitec conference and look forward to meeting you at the upcoming ceramitec, from May 17-20, 2021 in Munich!

A warm welcome to the digital AM Ceramics ceramitec conference! Unfortunately we are not able to welcome you as planned at the Fraunhofer Institute for Ceramic Technologies and Systems IKTS in Dresden to demonstrate the current developments and ideas in the ceramic world live. In order to succeed in this new, hitherto unknown format of the event, new challenges are posed to you and the organization team. Fortunately, we can rely on a strong interdisciplinary team at our partners Lithoz and Messe München as well as here within IKTS -many thanks at this point to everyone involved. Interdisciplinary teams are also needed to meet the new challenges currently facing the ceramics industry. We can only meet the ever-increasing demands of customers and legislators if we adapt the rapid developments in other disciplines to applications in the ceramic world. We hope that the lecture program will give you an interesting insight into the current trends as well as many suggestions for developments and cooperations and wish you an exciting conference.

THE FUTURE OF CERAMICS IS NOW.

A VIRTUAL WELCOME

Dr. Johannes Benedikt, CTO and Dr. Johannes Homa, CEO, Lithoz GmbH

Gerhard Gerritzen, Member of the Management Board, Messe München GmbH

Dr. Tassilo Moritz, Group manager Shaping & AM, and Uwe Scheithauer, Researcher, Fraunhofer IKTS


WEDNESDAY | 16TH SEPTEMBER 2020 THURSDAY | 17TH SEPTEMBER 2020

08:30 – 09:00Keynote: Multi-materials additive manufacturing and 5D printingProf. Alexander Michaelis | Fraunhofer IKTS

09:00 – 09:30Digital lab tour: additive manufacturing technologies at Fraunhofer IKTS

09:30 – 09:45A view beyond – video snacks and insightsfeatured by Lithoz GmbH and Messe München GmbH

09:45 – 11:15

COMPONENTS AND THERMAL PROCESSINGThe rocky road from idea to product: product development using the example of multiphase ceramics – a field report Dr. Tobias Fürderer | DOCERAM Ingenieurkeramik GmbH, Moeschter Group

Ceramic packages for magneto-resistive sensors in space applications Christian Melzer | RUAG Space Germany GmH

Advances in the debinding and sintering of ceramics under air and modified atmospheres Dr. Christian Schenk | Carbolite Gero GmbH & Co. KG

11:15 – 11:30A view beyond – video snacks and insightsfeatured by Fraunhofer IKTS

11:30 – 13:00

DATA COLLECTION AND PROCESSINGNon-contact infrared temperature measurement in inline process controlDaniel Wagner | DIAS Infrared GmbH & Johannes Abel | Fraunhofer IKTS

AI in practice: intelligent solutions for the sustainable optimization of ceramic process chainsDr. Martin Juhrisch | Symate GmbH

Data acquisition and analysis for process monitoring in the field of additive manufacturingDr. Valentin Lang | TU Dresden

Synopsis

08:30 – 09:00Keynote: Empowering digital transformation with additive manufacturing technologies Dr. Johannes Homa | Lithoz GmbH

09:00 – 09:15A view beyond – video snacks and insightsfeatured by Fraunhofer IKTS

09:15 – 10:45

TECHNICAL AND MEDICAL APPLICATIONSOsteoconduction and bone augmentation: When 3D-printed designs meet bone biologyProf. Franz Weber | University of Zurich

Tribo-mechanical behavior of semi-porous parts for small joint arthroplastyAmbra Paterlini | Lincotek Medical

Ceramic additive manufacturing for RADAR applicationsProf. Niels Benson | University of Duisburg

10:45 – 11:00A view beyond – video snacks and insightsfeatured by Lithoz GmbH

11:00 – 12:40

NEW DEVELOPMENTS IN MATERIAL AND TECHNOLOGYAdditive manufacturing of aluminum nitride ceramicsDr. Thomas Konegger | TU Wien

Multi Material jetting of ceramic componentsSteven Weingarten | Fraunhofer IKTS

Additive manufacturing of zirconia ceramicsDr. Erik Adolfsson | RISE Research Institute Sweden

Synopsis

PROGRAM


DIGITAL INSIGHTS DID YOU KNOW...?

Initially, we planned to welcome you at Fraunhofer Institute for Ceramic Technologies and Systems IKTS in Dresden and to give you insights in our research work during a guided tour through our laboratories. Now, having a digital conference, we have to adjust our plan.

Follow us on our digital lab tour! We would like to present our additive manufacturing technologies as well as the powerful infrastructure and research facilities at Fraunhofer IKTS.

Starting with the ceramic process chain, we present the following four additive manufacturing processes:

• VAT Photo Polymerization (VPP)• Fused Filament Fabrication (FFF)• Binder Jetting (BJ)• Multi Material Jetting (MMJ)

Please feel free to ask your questions and comment after the presentation.

During the breaks you will get more insights into our research and development topics, tech-nologies and events in short videos.

DIGITAL LAB TOUR: ADDITIVE MANUFACTURING TECHNOLOGIES AT FRAUNHOFER IKTS

A VIEW BEYOND

UWE SCHEITHAUERFraunhofer Institute for Ceramic Technologies and Systems IKTS, Dresden, Germany

[email protected]

VIDEO SNACKS AND INSIGHTS - BREAKS -

Lithoz GmbHMesse MünchenFraunhofer IKTS

The conference will be recorded to make it available to all registered participants for repeat-ed/post-event viewing within a fixed time frame of 14 days after the event.

You will receive the access link a few days after the event, due to technical reasons.

POST-EVENT VIEWING

EVENT RECORDING


VITA ABSTRACT

PROF. ALEXANDER MICHAELISFraunhofer Institute for Ceramic Technologies and Systems IKTS, Dresden, Germany

[email protected]

Prof. Alexander Michaelis studied physics at University of Dusseldorf, Germany. After switch-ing to the field of physical chemistry he received his docorate in electrochemistry. In 1996 he accepted a position at Siemens AG working as senior integration engineer in East Fishkill, New York, before he began to work for the corporate research department of Bayer AG in Leverkusen, Germany in 2000. From there he was delegated to H.C. Starck GmbH, where he was head of the Electroceramics and the New Business Development department. Further-more, he was managing director of InDEC B.V. working in the field of solid oxide fuel cells. During this time he also finished his state doctorate at University of Dusseldorf.

He became the president of the Fraunhofer Institute for Ceramic Technology and Systems IKTS in 2004 and holds the chair of Inorganic Nonmetallic Materials at Technische Universität Dresden. Recently he has been elected as president of the German Ceramic Society (DKG). Additionall he has been elected as a member of the Energy Advisory Board of Saxony.

The American Ceramic Society (ACerS) named him “Fellow of the Society“ for his long com-mitment and outstanding contributions to applied research and development of advanced ceramics. Among other awards and nominations he received the Fraunhofer Medal for out-standing achievements in the field of applied materials research in 2014.

Additive manufacturing with ceramic materials is particularly challenging due to the needed pre- and post shaping processes such as ceramic paste or ink preparation and thermal post treatment (sintering). In the case of multi-materials printing, the thermal expansion behavior of the materials have to be carefully adjusted for the co-sintering process. An important demand for all AM technologies is the improvement of reliability and performance of the man-ufactured components. Due to the time-consuming manufacturing processes and the lay-er-wise building process it is necessary to control the quality of each layer in order to repair a defect layer or to stop the building process to avoid waste of time and expensive material loss. Therefore, it is important to access the quality of the printed parts as early as possible. This requires in-operando non-destructive evaluation methods. For this, we present new optical methods such as laser speckle spectroscopy and optical coherence tomography.

For a further functionalization of the AM parts, 2D printing technologies are applied. We present first results on this combination of 3D and 2D printing that we call 5D printing.

MULTI-MATERIALS ADDITIVE MANUFACTURING AND 5D PRINTING

KEYNOTE


VITA ABSTRACT

DR. JOHANNES HOMALithoz GmbH, Germany

[email protected]

Dr. Johannes Homa holds a PhD in materials science from the Vienna University of Technolo-gy and has worked in additive manufacturing since 2003.

He is co-founder and managing director of Lithoz GmbH (www.lithoz.com), the world leader in additive manufacturing of advanced ceramics. Dr. Homa is founder of the initiative AM Austria (www.am-austria.com).

He is technical director of the Austrian 3D Printing Forum (www.3d-printing-forum.at) and co-inventor of several patents and author of numerous publications in the field of additive manufacturing.

With the current situation limiting physical interaction, digital communication strategies have allowed organisations and businesses to stay connected and continue making progress. Digital manufacturing technologies are also being effectively utilized by different industries to overcome the shortcomings of conventional forming technologies. Digital storage and independency from suppliers are, along with the freedom of design, some of the main advantages motivating companies to adapt and use additive manufacturing for their own fields. Additionally, we are seeing a growing trend of decentralized manufacturing where the final product is produced closer to or directly at the end consumer’s location.

In a world that is becoming ever more digital, additive manufacturing has a bright and bold future ahead. The innovation potential offered by these technologies is huge, particularly when it comes to new application development; entirely new markets and revenue streams have been pioneered using these latest product offerings. However, innovation comes not only from developing applications, but also from new machines, technologies and materials.

EMPOWERING DIGITAL TRANSFORMATION WITH ADDITIVE MANUFACTURING TECHNOLOGIES

KEYNOTE


VITA ABSTRACT

DR. TOBIAS FÜRDERERDOCERAM Ingenieurkeramik GmbH, Moeschter Group, Dortmund, Germany

[email protected]

Co-authors: S. Schomer (DOCERAM Ingenieurkeramik GmbH)

Dr. Tobias Fürderer was born in 1971 in Baden-Baden, Germany. He is the head of development at DOCERAM Ingenineurkeramik GmbH, Moeschter Group.

Starting in 1993 to 1999 he studied engineering, focusing on material science at University Aachen, where he became a degreed engineer. Fürderer earned his doctor degree on "Process optimization by adapted surfaces in chemical fibers processing" in 2007. From 1999 to 2004 he worked as an assistant researcher at university Aachen before becoming the product and development manager at DOCERAM Ingenieurkeramik GmbH in Dortmund, Germany, until 2011. Fürderer was the division manager from 2007 to 2011 at DOCERAM Medical Ceramics GmbH and became head of the R&D Moeschter Group in 2012. Since 2015 he is a member of the executive board of Moeschter Group Holding. Starting in 2004 until today he is also a member of the DIN Norming Commitee 14 Dental Ceramics. As well as a member of the VDI Working group 105 Additive Manufacturing, since 2019.

His fields of work comprise advanced ceramic materials and processes, medical ceramics for dental application and agile methods for developing hardware products.

When a product succeeds in the market, the time and efforts that have led to this are usually invisible. So are all of the failed projects that came before this successful one. But the development of a product is a journey rather than a destination and it is important to be able to take turns and avoid dead ends in order to arrive.

This presentation covers the story of an ongoing project from the beginning to the final marketing of the products and described all the pitfalls and challenges developers, project managers and sales people face when embarking on the adventure of a new product. The first ideas have to be evaluated and the application must be defined. But when the applications evaporate, what do you do? The most competent development partner must be found. But what to do if they drop out? Usually there is a major market you focus the product on. Then along comes a reorganization and completely wrecks your beautifully engineered plans. But is this a reason to give up already?

An agile mindset and robust networks combined with good project management help to cope with these challenges and lead to good results.

THE ROCKY ROAD FROM IDEA TO PRODUCT: PRODUCT DEVELOPMENT USING THE EXAMPLE OF MULTIPHASE CERAMICS - A FIELD REPORT

SESSION 1: COMPONENTS AND THERMAL PRESSING


VITA

ABSTRACT

CHRISTIAN MELZER RUAG Space Germany GmbH, Coswig, Germany

[email protected]

Co-authors: Tilo Schmidt (RUAG Space Germany GmbH)

Christian Melzer is a project manager at RUAG Space Company in Germany.

He was born in Weißenfels, Germany in 1981 and completed his studies for Mechanical Engineering at Technische Universität Dresden in 2007. Afterwards he worked as an analysis engineer at the Fraunhofer Institute for Nondestructive Testing IZFP in Dresden. He became the technical lead and a project manager at HTS GmbH in Coswig, Germany in 2011 and stayed there until he started his work for Jena-Optronic GmbH in 2015. In Jena, Germany he did project management for assembly, integration and tests. After leaving Jena, Melzer came back to work for HTS GmbH. This time as the Additive Manufacturing team leader, while also working in project management and aquisition. He holds the same position at RUAG Space Germany GmbH in Coswig, Germany since 2018.

His fields of work comprise project management, space systems and mechanisms and additive manufacturing.

In most spacecraft mechanisms used today, the angular position is measured using potenti-ometer or optical encoders. On the one hand, potentiometers provide moderate performance at very low costs, however, are often characterized by low reliability. On the other hand, optical encoders provide very high performance but are rather sensitive to radiation. In addi-tion, costs are significant. Since 2015 RUAG Space Germany, together with Sensitec GmbH, develop a sensor system called "Magneto Resistive Angular Sensor for Space Applications" (MRS), which is an angular sensor based on the Magneto-Resistive effect, specifically devel-oped for the use in spacecraft mechanisms. In the frame of this activity ceramic packages for carrying the MRS under space environment has been developed, designed, manufactured and tested. The work described in this report was done under ESA Contract. Ceramic AM tech nology was investigated under the focus of cost-effective production of a small batch size. The main technical challenges were:

• High demands on manufacturing tolerances of the package to meet performance requirements of the sensor

• To produce hermitically sealed vias for electrical contacting of the chip in the ceramic package

• Package closure by solderingThe final performance tests provided evidence in terms of high precision manufacturability of ceramic packages. It can be stated that the accuracy of 0.1 ° [+/-0.05 ° linearity error] can be achieved under all tested environmental conditions.

The paper will give an overview of the design of the ceramic package needed to accommo-date the sensor circuit. The testing of the finally produced batch is presented and some lessons learned will be discussed.

CERAMIC PACKAGES FOR MAGNETO-RESISTIVE SENSORS IN SPACE APPLICATIONS



VITA ABSTRACT

DR. CHRISTIAN SCHENK Carbolite Gero GmbH & Co. KG, Neuhausen, Germany

[email protected]

Dr. Christian Schenk was born in Heidelberg, Germany in 1980. He is a Project Manager at Carbolite Gero GmbH & Co. KG since 2014.

He received his Diploma in chemistry in 2006, and gained his PhD in chemistry three years later at the Karlsruhe Institute of Technology, Germany. In 2011 he earned his postdoctoral degree at the Monash University in Melbourne, Australia.

Dr. Schenk is an expert in the field of high-temperature heat treatment up to 3000 °C.

CARBOLITE GERO stands for the highest quality and technological leadership in the devel-opment and production of ovens for laboratory and industry in the temperature range up to 3000 °C and accompanies the rapid development in the 3D printing area with new innovative solutions in furnace construction.

Since the prehistoric clay pottery development high-temperature furnaces for the debinding and sintering of ceramics are one of the oldest high technologies in human history and face new challenges with 3D printed ceramic parts.

Printed ceramic parts sometimes have large component dimensions in combination with large variances in the wall thicknesses and therefore pose great challenges in terms of fur-nace geometry, gas flow and temperature distribution. For this purpose, CARBOLITE GERO offers ceramic fiber-insulated furnaces up to 1800 °C in air and cold-wall vacuum chamber furnaces (with tungsten or graphite heating) up to 2200 °C under inert gases, hydrogen or high vacuum, which are adapted to special sintering conditions. During this brief presenta-tion we will show application examples in different furnaces.

ADVANCES IN THE DEBINDING AND SINTERING OF CERAMICS UNDER AIR AND MODIFIED ATMOSPHERES



VITA ABSTRACT

DANIEL WAGNERDIAS Infrared GmbH, Dresden, Germany

[email protected]

Co-authors: Mario Kerl, Günter Hofmann (DIAS Infrared GmbH)

Daniel Wagner is part of the DIAS Infrared GmbH in Dresden, Germany.

Born in 1977 in Saalfeld, Germany, he has been working in the department Application and Sales since 2007. Before working for DIAS he was working in Research and Development at KLEIBER Infrared GmbH in Saalfeld, starting in 2003 until 2007.

Wagner got his diploma in electrical engineering.

His main working area is infrared temperature measurements for industrial and research areas.

In industrial process measurement technology, non-contact infrared temperature measure-ments between -40 °C and 3000 °C are a very important part. For this purpose, a large number of pyrometers for point temperature measurement and thermal imaging cameras for measuring temperature distributions are available.

The spectral ranges of these devices vary from 0.8 μm to 1.8 μm (NIR) to 3 μm to 5 μm(MWIR) for high and medium temperatures up to 8 μm to 14 μm (LWIR) for low temperature measurements. In order to minimize measurement errors caused by emissivity, the measure-ments should be done in the shortest possible wavelength and in wavelength ranges of high emission.

In the first part of this presentation an overview of infrared temperature measurement techniques is given. New fast MWIR pyrometers based on infrared semiconductor sensors will be described in more detail as they are used in the following application example.

NON-CONTACT INFRARED TEMPERATURE MEASUREMENTS IN INLINE PROCESS CONTROL, PART 1



VITA ABSTRACT

JOHANNES ABELFraunhofer Institute for Ceramic Technologies and Systems IKTS, Dresden, Germany

[email protected]

Co-authors: Steven Weingarten, Tassilo Moritz (Fraunhofer IKTS)

Johannes Abel is working as a scientific assistant at Fraunhofer Institute for Ceramic Technologies and Systems IKTS in Dresden.

He was born in 1986 in Dresden, Germany. Studying at Technische Universität Dresden he earned his diploma as a process engineer in 2012.

His main working fields include ceramic injection molding and additive manufacturing of technical ceramics.

The second part of this presentation shows some results for inline process control inadditive manufacturing of ceramic components. For this purpose the Fused FilamentFabrication (FFF) process was chosen in which a highly filled thermoplastic Al2O3 filament is melted in a heated nozzle and placed underneath. The material is solidified by cooling after its deposition. This results in a component built up layer by layer. To investigate the thermal conditions of the extruded material close to the nozzle a pyro- meter was attached to a commercial FFF printer and the deposition of superimposed layers was thermally monitored.

The type of defects introduced has been chosen on the basis of defects occurring during printing (over extrusion, short material dropout, layer binding defect).The insertion of defects could be detected by means of the high resolution IR-sensor technology which can path the way for inline process control of thermal AM processes.

The work on fast MWIR pyrometers and application investigations of additive manufacturing processes for ceramic components are funded by the German Federal Ministry of Economics and Energy within a ZIM cooperation project.

NON-CONTACT INFRARED TEMPERATURE MEASUREMENTS IN INLINE PROCESS CONTROL, PART 2



VITA ABSTRACT

DR. MARTIN JUHRISCH Symate GmbH, Dresden, Germany

[email protected]

Dr. Martin Juhrisch has been managing director of Symate GmbH since 2012. In this position he is responsible for the areas of organization and sales. The successful spin-off of the TU Dresden develops, installs and supports the AI-Dashboard Detact — a software system for the systematic optimization of complex process chains with the methods of artificial intelligence.

By correlating process variables and QA data, "Detact® AI Infrastructure & Apps" digitally maps the manufacturing process and thus creates a selfdiagnosing production environment. This increases the stability of the processes and quality fluctuations are detected early. The browser-based system makes use of the possibilities of IIoT and offers flexible functionalities for targeted component and process design. This gives users a more detailed understanding of the process and a digital assistant for a wide range of scenarios relating to their production process.

Until Symate was founded, Juhrisch was head of the "Exist-Research Transfer Tec-In" at the Institute for Control Engineering at the TU Dresden and worked on the DFG project "MIRO" at the University of Münster.

Production managers are usually particularly interested in technology data when problems occur or when the optimal setting parameters are being searched for during the start of operation. Although more and more data is measured and recorded throughout the entire process chain, the longest time - namely when the process is running - the potential of the permanently accruing production data is wasted. Symate presents its development Detact — a platform with which distributed, heterogeneous data from the most diverse sources, such as plant control systems, sensors, databases and even manual protocols, can be linked to one another and parameter interactions detected throughout the entire process.

Using practical examples, the speaker will show how the participants can make use of existing data from their machines and systems, from the process and from the products manufactured in each case, without fundamentally changing existing systems.

The use of artificial intelligence (AI) - encapsulated in Detact Apps — to support machine operators and engineers is demonstrated on real process chains. Last but not least, the par-ticipants will recognize where the greatest potentials of digitization lie and how optimization experiences from small pilot projects can be transferred to complex factories.

AI IN PRACTICE: INTELLIGENT SOLUTIONS FOR THE SUSTAINABLE OPTIMIZATION OF CERAMIC PROCESS CHAINS



VITA ABSTRACT

DR. VALENTIN LANGTU Dresden, Dresden, Germany

[email protected]

Co-authors: Michael Schwarzenberger, Hajo Wiemer (TU Dresden)

Dr. Valentin Lang is a research associate at Technische Universität Dresden in Dresden, Germany.

Born in 1988 in Forst, Germany, he studied engineering at TU Dresden from 2007 to 2014. He earned his PhD at the same university in 2019. He was a research associate at the Fraunhofer Institute for Material and Beam Technology IWS in Dresden for five years, until 2019.

Lang is a member of the German Physics Association.

His working fields include additive manufacturing, machine learning and photonics.

Artificial Intelligence (AI), Additive Manufacturing and Industry 4.0 are being attributed major impact on economy, existing production and application systems. To address these ‘disrup-tive‘ technologies in combination is an obvious conclusion. AI comprises procedures helping machines perceiving their environment, drawing logical conclusions and acting accordingly, thus representing a broad spectrum of data processing in fields like linguistics, image pro-cessing, motor and robotics. AI is promising in optimization problems, as causes of problems can be identified and dependencies drawn automatically. Quality management urges for the systematic determination of problem causes, analysis and structuring of processes, as well as for visualization and weighting of relationships in complex structures. Challenges to the application of AI in manufacturing include the interaction of complementary competencies uniting information technology and manufacturing knowledge. In this context, established holistic data based optimization methodologies are presented. One use case is the acquisi-tion of the 3D printing workflow, which enables the analysis of key steps in production management. Further, it is presented how AI can contribute to improving the 3D printing process by evaluating and predicting quality of the printing process in order to avoid errors in the final product and thus lead to better results. As a key aspect of AI-oriented optimization strategies, the acquisition of data inspecting process characteristics, appropriate sensor and machine data sources as well as adequate evaluation strategies are discussed.

DATA AQUISITION AND ANALYSIS FOR PROCESS MONITORING IN THE FIELD OF ADDITIVE MANUFACTURING



VITA ABSTRACT

PROF. FRANZ WEBERUniversity of Zurich, Zurich, Switzerland

[email protected]

Prof. Franz Weber graduated from the University Konstanz, Germany with a PhD in Biology/ Muscle Biochemistry. He completed a 3-year postdoctoral training on muscle cell biology at Cornell University Medical College, New York City and served as a lecturer in the Department of Cell Biology and Anatomy. He spent the following two years at Biochemistry of the ETH Zurich working on the lipid uptake from the small intestine. In 1995, he joined the Department of Cranio-Maxillofacial and Oral Surgery at the University Hospital Zurich, and the Dental School of the University Zurich. From 2005 to 2009, he was Director of the European Techni-cal Center of Inion Ltd in Cambridge.

He is currently appointed as Professor of Craniofacial and Oral Biotechnology/Bioengineering at the Center of Dental Medicine of the University of Zurich, member of the Medical and the Science Faculty of the University of Zurich, and as visiting Professor in the Dental School at the University of Hong Kong. Furthermore, he is a member of TERMIS (Tissue Engineering international & Regenerative Medicine Society), IADR (International Association for Dental Re-search), DKG (German Ceramic Society), ACerS (The American Ceramic Society), and SSB+RM (Swiss Society for Biomaterials and Regenerative Medicine).

His main areas of interest are osteoconduction, scaffold design, bone growth and pulp regen-eration. His research encompasses additive manufacturing, bone substitutes, osteoconduc-tion, bone morphogenetic proteins, delivery systems, epigenetics, and in vitro bone tissue engineering.

In the last decades, advances in bone tissue engineering mainly based on osteoinduction and on stem cell research. Only recently, new efforts by others and us focused on the micro- and nanoarchitecture needed to improve and accelerate bone regeneration. By the use of additive manufacturing, libraries of diverse microarchitectures were produced and tested to identify the ideal pore size or rod distance for osteoconduction to occur. Presently, we try to elucidate the dependency of osteoconduction on microporosity and expand our view on micro- and nanoarchitecture of bone substitutes for optimal bone augmentation.

For the production of scaffolds, we applied for titanium-based scaffolds selective laser melting and for ceramics the CeraFab 7500 from Lithoz, a lithography-based additive manufacturing machine. As in vivo test model, we used a calvarial defect and a bone augmentation model in rabbits. The histomorphometric analysis showed that bone formation was significantly in-creased with pores between 0.7 - 1.2 mm in diameter. Moreover, microporosity appeared to be a strong driver of osteoconduction and influenced osteoclastic degradation. Best microarchitec-ture for osteoconduction and bone augmentation are different.

In essence, additive manufacturing enabled us to generate libraries of microarchitectures to search for the most osteoconductive microarchitecture and the ideal microarchitecture for bone augmentation purposes. Moreover, additive manufacturing appears as a promising tool for the production of personalized bone tissue engineering scaffolds to be used in cranio-max-illofacial surgery, dentistry, and orthopedics.

OSTEOCONDUCTION AND BONE AUGMENTATION: WHEN 3D-PRINTED DESIGNS MEET BONE BIOLOGY



VITA

ABSTRACT

AMBRA PATERLINILincotek SpA, Trento, Italy

[email protected]

Co-authors: M. Schwentenwein, M. Piccinini, A. Stamboulis (Lincotek SpA)

Ambra Paterlini was born in Italy in 1992. She currently is a PhD Fellow at Lincotek Medical, working also for the University of Birmingham, UK and Lithoz GmbH, Austria.

She received her Bachelor`s Degree in Environmental Engineering at "Enzo Ferrari" Department of Engineering at UNIMORE in Modena, Italy. She graduated with her Master`s Degree in Materials Engineering at the same place in 2017.

Starting in 2014, she worked in the department of Quality Control for ceramic materials and sustainability at Casalgrande Padana SpA, Casalgrande, Italy. In 2016 she completed her Master Thesis project "AlSi-polyester abradable coatings for turbines" at the IRTES-LERSMPS Laboratories at University of Belfort, France. She has been a research engineer at the CIRIMAT Laboratories in Toulouse, France from 2017 to 2018, within the areas of bio-resorb-able scaffolds by robocasting and cold sprayed coatings for orthopaedics.

Her main areas of interest are biomaterials and bioceramics, as well as lithography- based and material extrusion Additive Manufacturing and coatings for orthopaedics.

Ceramics have a long history in the biomedical field: from bone scaffolds to orthopaedic implants, their applications are various. This is mainly related to the high biocompatibility of these materials, because of their potential similarity to osseous matter. In particular, for joint replacements, high mechanical properties for parts and surfaces are required, so advanced ceramics as alumina and zirconia are preferred. Unfortunately, this specific surgery, also known as arthroplasty, is more and more required to treat one of the most diffused causes of disability worldwide: osteoarthritis. This disease is continuously spreading because of the longer life expectancy and the diffusion of obesity in Europe. Highly loaded parts, such as hip or knee prostheses, require strong mechanical prostheses, so metal components are pre-ferred – despite their lower osteointegration. On the other hand, there are several joints, often affected by arthritis, that don’t bear high loads. This project aims to create entirely ceramic parts for orthopaedic implants by taking advantage of benefits offered by lithography-based ceramic manufacturing. In particular, the high density achieved on printed parts (around 99 % after sintering) results in promising mechanical properties, comparable to conventional processed materials, while the good shape accuracy allows to reproduce details of around 25 μm. The main goal of this study is the production of semi-porous implants, to guarantee a high mechanical resistance and poor friction on joint head, as well as improved vascular-ization and bone adherence given by the porous surface. After an initial modeling simulation screening, mechanical analyses were carried out to compare the different lattice geometries: regular and randomized structures were evaluated. Alumina, zirconia and zirconia toughened alumina samples were compared in terms of tribological behavior – several parameters were considered: surface finishing, material combination and polishing treatment.

TRIBO-MECHANICAL BEHAVIOR OF SEMI-POROUS PARTS FOR SMALL JOINT ARTHROPLASTY



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PROF. NIELS BENSONUniversity of Duisburg-Essen, Duisburg, Germany

[email protected]

Co-authors: Masoud Sakaki (University of Duisburg-Essen and CENIDE), Alejandro Jiménez-Sáez, Martin Schüssler, Rolf Jakoby (TU Darmstadt)

Prof. Niels Benson received his Dipl.-Ing. degree in Electrical Engineering from the University of Stuttgart, in 2004, and his Dr-Ing. degree in Materials Science from the Technische Universität Darmstadt, in 2009.

Since 2008, he was a Senior Scientist for Polymer Vision on rollable active matrix displays. In 2010, he joined the University of Duisburg-Essen as a Research Group Leader on thin-film photovoltaics and electronics.

In 2018, he was appointed a W1-Professor with the University of Duisburg-Essen on printable materials for signal processing systems.

His current research interests include charge carrier transport in disordered semiconductor systems, passive chipless RFID systems, and additively manufactured ceramic components for sub-mm and mm wave signal processing applications.

Radio Detection And Ranging (RADAR) applications have long evolved from pure military purposes to civil applications, and have entered our everyday lives in many scenarios ranging from traffic control, such as autonomous driving, to weather forecasting. Here, we discuss a novel application, which will make mobile material transceivers for the generation of precise topography and material maps possible. This application can e.g. aid fire rescue operations by enabling an automated situation survey. For this purpose, sub-mm localization accuracies are required, which is only possible when RADAR technology is able to make use of the sub-mm wavelength range. However, when complex 3D structures are required, with structural features on the sub-500 μm length scale, the useability of classical subtractive manufactur-ing techniques is limited. This limitation is related to alignment issues and intermodulation losses, when multicomponent integration is required on the discussed length scale. Additive manufacturing in the form of "Lithography-based Ceramic Manufacturing" (LCM) is a potential solution for this issue. The LCM technology with a DLP-based pixel resolution of 25 μm and achievable ceramic densities of > 99 % has excellent boundary conditions for the implemen-tation of monolithic multi-component integration in mm- and sub-mm wavelength application scenarios. As a first step towards the realization of RADAR beacons, required for the mobile material transceiver application scenario with sub-mm localization requirements, we demon-strate the implementation of Al2O3 resonator structures at 90 and 230 GHz. The resonators exhibit high loaded quality factors of 486 and 376, as extracted from S-parameter measure-ments, and yield a stable electromagnetic device functionality up to temperatures of above T = 120 °C. These results substantiate the potential of the LCM technology for mm and sub-mm wave applications, and are a promise of things to come in this new field of research.

CERAMIC ADDITIVE MANUFACTURING FOR RADAR APPLICATIONS



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DR. THOMAS KONEGGER TU Wien, Vienna, Austria

[email protected]

Co-authors: Johannes Rauchenecker (TU Wien), Anna-Katharina Hofer, Julia Rabitsch, Martin Schwentenwein (Lithoz GmbH)

Dr. Thomas Konegger was born in 1982 in Villach, Austria. He currently holds the position of assistant professor for Structural Ceramics at TU Wien in Vienna, Austria. At the same university he got his MSc in Technical Chemistry in 2007, before gaining his PhD in Technical Chemistry in 2010.

Afterwards Konegger was head of the "High-Performance Ceramics" group and a Post- Doctoral University Assistant at TU Wien from 2010 until 2018, when he started as assistant professor. From 2013 to 2014 he was a Erwin Schrödinger-Fellow at Clemson University, USA.

Since 2020 Dr. Konegger is a member of the Austrian Ceramic Society. His working fields concentrate on the processing of polymer-derived ceramics, the development and charac-terization of porous ceramics and materials development for additive manufacturing of ceramics.

An increasing industrial and technological demand to solve thermal management challenges, resulting from miniaturization and increasing power densities in electronic components, suggests the prospective application of aluminum nitride (AlN), a ceramic material with outstanding thermal, chemical, and electric characteristics. As con-ventional ceramic processing techniques are highly limited in terms of available component shapes, it was the objective of this work – carried out in the FFG-funded ADDHANCE project – to develop new AlN-based materials systems suitable for additive manufacturing employing the lithography-based ceramic manufacturing (LCM) technology. In a first step, AlN powder compositions with varying sintering additive mixtures were evaluated in terms of consoli-dation properties during sintering at atmospheric pressure, using test specimens shaped by conventional cold-isostatic pressing. After screening of the densification behavior, the most promising compositions were tailored towards maximi- zation of thermal conductivity values, reaching thermal conductivities up to 180 W m-1 K-1. Subsequently, the insights were transferred towards the development of AlN-based slurries facilitating LCM, allowing for the fabrication of additively manufactured AlN-based green bodies. By employing a well-tailored debinding regime followed by sintering at up to 1700 °C, LCM-shaped AlN materials with near-full densification were obtained. In-depth characteriza-tion of sintered specimens showed that AlN specimens prepared by LCM are indeed compara-ble to conventionally consolidated materials in terms of both mechanical and thermal char-acteristics. The project results demonstrate the high potential of the LCM technology for obtaining complex-shaped AlN ceramics with exceptional thermal properties in combination with chemical and thermal stability, rendering this technology highly relevant for prospective applications involving high-power electronics, as mounts for LEDs, nozzles used in plasma spraying processes, heat exchangers operating in aggressive environments, or heat dissipa-tors in high-speed trains.

ADDITIVE MANUFACTURING OF ALUMINIUM NITRIDE CERAMICS



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STEVEN WEINGARTEN Fraunhofer Institute for Ceramic Technologies and Systems IKTS, Dresden, Germany

[email protected]

Steven Weingarten, born in 1987 in Wernigerode, Germany, is working as a scientific assistant at Fraunhofer IKTS in Dresden since 2017.

Weingarten got his diploma as a materials scientist at Technische Universität Dresden in 2017.

His main working area is within the field of additive manufacturing of technical ceramics. Here, he is responsible for the Multi Material Jetting (CerAM MMJ) technology.

The trend towards functionalization, miniaturization and individualization can be found in many branches of industry and can be implemented today thanks to the further development of additive manufacturing methods and the use of plastics, synthetic resins, and metals for a variety of components or end products. It becomes problematic, however, when the demands on the materials for the components increase in order to withstand high temperatures, chem-ical attacks or even mechanical loads. In this case, the common materials fail and ceramic materials must be used. In order to meet the requirements for novel components, Fraunhofer IKTS in Dresden developed Multi Material Jetting (CerAM MMJ, previously Thermoplastic 3D-Printing). This technology offers the possibility to additively manufacture functionally graded components (FGC) and thus to realize novel products. In the CerAM MMJ technolo-gy, melted particle-filled thermoplastic feedstocks are selectively deposited as individual drops and fused directly during deposition, resulting in a three-dimensional component, the so-called green body, which subsequently has to be thermally processed. The focus here is on the processing and combination of high-quality ceramic and metallic materials such as zirconium oxide and stainless steel or electrically conductive silicon nitride with electrically insulating silicon nitride. Through the parallel use of up to four dosing systems, up to four different materials or material mixtures and thus their specific properties can be combined in one ceramic, metallic or metal-ceramic component within one manufacturing process for the first time. The MMJ device was also developed by Fraunhofer IKTS and will be commercially available in the near future. The presentation gives an overview of the current developments regarding a new generation of the 3D printer, material developments and methods for inline process control.

MULTI MATERIAL JETTING OF CERAMIC COMPONENTS



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DR. ERIK ADOLFSSONRISE Research Institutes of Sweden, Gothenburg, Sweden

[email protected]

Co-authors: Emil Johansson, Gustavo Lanos and Fredrik Silvermyr (RISE Research Institute Sweden)

Erik Adolfsson is working as a researcher at RISE Research Institutes of Sweden and is active in areas related to process development, manufacturing and evaluation of engineering ceramics.

The work performed to develop new suspensions for additive manufacturing of zirconia materials will be presented. The work includes powder preparation, where the powders were ball milled, freeze granulated, freeze dried and then finally mixed with the monomer system to obtain a printable zirconia suspension. The additively manufactured materials were prepared in a Lithoz Cerafab 7500 printer using different printing parameters. The debinding of the prepared materials have been studied by special debinding furnace and based on the results, debinding cycles for high temperature furnaces have been designed. The main focus of the work has been to develop a reliable process to prepare materials that can be mechanically evaluated, which has been a general problem for additively manufactured ceramics. By changing the composition, printing pa-rameters, debinding cycle, the result have slowly been improved and the frequency of the cracks present been reduced.

The process developed have now reached a level where bending bars are printed, debinded and sintered without problems with delamination. Such a reliable manufacturing process is the first step to allow the influence from different process parameters on the material performance to be evaluated.

ADDITIVE MANUFACTURING OF ZIRCONIA CERAMICS


Imprint

Lithoz [email protected]

www.lithoz.com

ceramitec [email protected]

Fraunhofer [email protected]

www.ikts.fraunhofer.de

www.am-ceramics.dkg.de

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